Apparatus for the separation of fluid cracking catalyst particles from gaseous hydrocarbons

ABSTRACT

Catalyst and hydrocarbon vapors are separated in a cyclone zone attached to the discharge of a riser cracking operation. A vortex stabilizer separating the cyclone zone from a stripping zone allows stripping gas from the stripping zone to be passed upwardly into the cyclone zone countercurrent to the downward flow of catalyst, thereby improving the separation and stripping of gaseous hydrocarbons from separated catalyst. The combined cyclone-stripping zone reduces catalyst hydrocarbon contact time, thereby improving gasoline yield and olefin content, decreasing gas make, and reducing coke deposits.

This is a division of application Ser. No. 452,599, filed Dec. 23, 1982and issued as U.S. Pat. No. 4,455,220 on June 19, 1984.

BACKGROUND OF THE INVENTION

This invention relates to a process and apparatus for improving theseparation of fluid cracking catalyst particles from gaseoushydrocarbons and stripping of hydrocarbons from the catalyst. Moreparticularly, the invention is concerned with improving the separationof catalyst particles from gaseous hydrocarbon conversion products froma riser reactor in a catalytic cracking process and improving thestripping of hydrocarbons from the separated catalysts.

Dehne, U.S. Pat. No. 3,802,570 and Giles, U.S. Pat. No. 4,212,653describe cyclone separators which include vortex stabilizing means forimproving separation efficiency.

Anderson, et al., U.S. Pat. No. 4,043,899 and Heffley et al., U.K. Pat.App. No. 2,013,530 A, describe cyclones which have been modified toinclude a separate cyclonic stripping of catalyst separated fromhydrocarbon vapors from a riser cracker.

Dries, U.S. patent application Ser. No. 4,313,910 describes an apparatusfor separating a carrier gas from a particle stream from a riser reactorby deflecting the particle stream about a curved surface and introducinga fluid such as steam to rapidly disengage hydrocarbons from thecatalyst particles.

The use of zeolite cracking catalysts, requiring short, fixed reactiontimes, has substantially affected catalytic cracking process designduring the last few years. Modern catalytic cracking technology usesriser reactors, with rapid solid-vapor disengaging at the riser exit. Inthis process, the traditional reactor vessel has been relegated to therole of solids disengaging (i.e., gravity settler). Several designs arecommercially available to treat the unique reaction engineering problemsassociated with fast-fluidized riser reactors. Numerous problems,regarding vapor/catalyst disengaging, remain to be solved. Severalmethods and means for solving these problems are proposed in theabove-described patents which are incorporated herein by reference.However, none of the above describe the present invention.

The benefits of good feed/catalyst contacting include greater gasolineyield, a less pronounced catalyst density gradient (radially), fasterfeed vaporization, lower gas mix, and generally improved operability. As"ultimate" yields in zeolitic cracking are approached, engineering andhardware limitations will most certainly govern operations and thecracking reaction scheme itself.

Effectively terminating cracking reactions at the riser exit to accruebenefits of increased gasoline make, decreased gas make, and a moreolefinic product requires stripping of interstitial and adsorbedhydrocarbons in the vapor/solids disengaging device. Increased gasolineyields result from a reduction in excessive secondary reactions, whichoccur if the hydrocarbons remain in contact with the catalyst beyond adesirably short reaction time. Those catalytic cracking units with gascompressor throughput capacity limitations will immediately benefit fromthe reduced gas production resulting from rapid vapor/catalystdisengaging and quick stripping of interstitial hydrocarbon. Reducedamounts of entrained and adsorbed hydrocarbons going into theregenerator will benefit units which are "coke" burning limited.

The hydrocarbons which must be separated from the catalyst include thebulk product vapor, the interstitial vapor, and the adsorbed products.The bulk product vapor is that which is separated, quickly and easily,by mechanical means (cyclones). The interstitial vapor can be displaced,relatively rapidly, by "stripping" gas, preferably steam. The adsorbedproduct requires a longer time to desorb and requires additional steamstripping. It is an object of this invention to provide mechanicaldisengaging/quick stripping to separate the bulk and interstitial vaporsfrom the cracking catalyst as rapidly as possible. This minimizesovercracking and reduces the amount of carbon deposited on the catalyst.It is a further object of this invention to provide additional strippingto remove adsorbed products as rapidly as possible.

Heretofore, the introduction of stripping gas into a cyclone separatorresulted in a loss of separation efficiency and was impractical.

It has now been found that when vortex stabilizing means areincorporated in a cyclone separator, stripping gas can be added to thecyclone separation zone without substantial loss of efficiency.Consequently, the cyclone separator and downstream stripper may becombined to achieve the concomitant benefits of quick stripping toremove bulk product vapor and interstitial vapor and to provide thelonger stripping time required to desorb adsorbed hydrocarbon productsfrom the catalyst.

SUMMARY OF THE INVENTION

The present invention provides a method and apparatus for separatingfluid cracking catalyst particles from hydrocarbon conversion productsand stripping gases therefrom which comprises passing a suspension ofsaid catalyst particles and gaseous hydrocarbons upwardly through ariser conversion zone in a fluid catalytic cracking process underelevated temperature conversion conditions; passing said suspension fromsaid riser conversion zone into the upper portion of a separator vesselcontaining a cyclonic swirl zone wherein a fluid vortex is formed fromwhich a cyclonic separation is made between catalyst particles andgaseous hydrocarbon conversion products in said cyclone zone; centeringthe tip of said fluid vortex by contact with vortex stabilizing meanshaving a diameter of about one vortex outlet diameter or greater andbeing coaxially located at the bottom of said separation zone; definingthe length of said separation zone by spacing said stabilizing means atleast about two vortex outlet diameters below the bottom of said vortexoutlet, which comprises an open ended vertical coaxial passagewayextending from the upper portion of the separator vessel downwardlythrough said swirl zone to the top of said cyclone zone; removingseparated gaseous hydrocarbon conversion products from the upper portionof the cyclone zone through said vortex outlet; passing separatedcatalyst through an annulus formed by the perimeter of said stabilizingmeans and the separator wall into a lower stripping zone which is ingaseous communication with the cyclone zone, said annulus beingsufficiently wide to permit catalyst passage downwardly and strippinggas passage upwardly; contacting said catalyst with from about 1 to 4pounds of stripping gas per 1,000 pounds of catalyst as it passesdownwardly through said annulus and a stripping zone to a catalyst bed,the length of said stripping zone being defined as the distance from thestripping gas/catalyst bed contact zone to said stabilizer means, saiddistance being sufficient to provide disengaging height between the topof said catalyst bed and the bottom of said stabilizing means so as toavoid slugs of catalyst carryover into said cyclone zone.

BRIEF DESCRIPTION OF DRAWING

FIG. 1 is a diagrammatic elevation of a test loop adapted to be used inaccordance with the invention.

FIG. 2 is a diagrammatic elevation of a stripper cyclone according tothe invention.

FIG. 3 is a graph which shows the effect of gas upflow on cycloneefficiency with and without stabilizer means.

FIG. 4 is a graph which shows the effect of the vortex stabilizer andcatalyst bed depth on stripper cyclone performance at various gasstripping rates.

DETAILED DESCRIPTION

Cyclones are particularly useful at high temperatures and pressuresbecause they are simple in construction, having no moving parts, havelarge capacities, and are not sensitive to the chemical nature of thegas or solid. On the other hand, cyclones require high internalvelocities to separate small particles efficiently. The high velocitiesin cyclones cause erosion, attrition, noise, and structural vibration.The errosion problem in particular becomes very costly when an FCC unitmust be shut down prematurely for cyclone repairs.

A cyclone separator uses the centrifugal forces in a confined, highvelocity vortex to separate phases of different densities. The strengthand stability of the vortex are of primary importance in determiningboth separation efficiency and erosion resistance of a cyclone. Sinceimproved cyclone reliability, separation performance, and erosionresistance are extremely important commercial objectives, studies wereundertaken to achieve cyclone modifications which will reduce erosionand improve efficiency. In particular, studies were made of cycloneinternals which contained means for stabilizing the vortex. By"stabilized", we mean that the vortex was held in the center of thecyclone and that the turbulent energy dissipation was reduced.

Numerous cyclone flow, velocity, acoustical, and pressure dropexperiments were performed at near ambient conditions. Most of theseexperiments were done with an 18 inch diameter, tangential inlet cyclonewhich was a 0.31 scale Plexiglass® (a shatter-resistant syntheticacrylate resin) model of a second stage FCC commercial cyclone. Thescale of the model was chosen to simulate the Reynolds and Strouhalnumbers of the actual FCC cyclone at a similar inlet velocity (25m/sec). The model was tested with and without vortex stabilizers ofvarious configurations. Wall roughness was simulated by a 10 mesh, 0.11cm "thick" wire screen closely fitted to the inside walls of thecyclone. This model is typical of cyclones used in modern catalyticcracking units, except that it is a particularly high efficiency design.The distinguishing features of such a design are a large inlet to outletarea ratio, narrow inlet, and long cyclone body.

Many variations of the basic cyclone were tested to determine theeffects of hopper geometry, stabilizer geometry, and wall roughness onthe vortex motion in cyclones.

All experiments used air (to simulate gaseous hydrocarbons) as the mainflow. The air was supplied by three 400 horsepower blowers, each withthe capacity of one standard m³ /sec (2100 ACFM). Most of theexperiments were done with about 0.6 m³ /sec at 117 kPa (17 psia). Thisflow rate corresponds to an inlet velocity of 17 m/sec. At this flowrate, the Reynolds number based on the outlet tube diameter (Re_(z)=ρ_(g) w_(i) r_(i) /μ) was approximately 2.8×10⁵. At such a highReynolds number the velocity profiles were essentially independent ofthe flow rate, therefore, the actual flow rate was allowed to varysomewhat, but all measurements were taken at flow rates above 0.5 m³/sec at 110-130 kPa, 16°-29° C. (16-19 psia, 60°-85° F.). For purposesof comparison, the velocity profiles were all adjusted to an inletvelocity of 17 m/sec.

Cyclones are characterized by large radial pressure gradients whichbalance the centrifugal forces in the swirling flow. Therefore, there isa relative vacuum at the center, or core, of the vortex. This lowpressure core would presumably draw on any nearby surface, thusstabilizing an attachment of the vortex to that surface.

Vortex stabilizer means were placed in the model cyclone to forestallthe unsteady motion of the vortex.

A vertical pin or vortex finder may be added to the stabilizer torestrict and center the lateral motion of the vortex. It was found thata 0.6 cm diameter stabilizer pin was insufficient to restrict the vortexmotion in the test cyclone. The vortex stabilizer was more effectivewhen a larger pin was used to center the vortex. A 1.9 cm diameter rodwas tested with better results.

Several types of vortex stabilizer means were tested with varyingresults. Generally, a flat plate or circular disk was found to besatisfactory. The vortex stabilizer means diameter should be at leastabout one vortex outlet tube diameter. The maximum stabilizer diameterin a commercial model is set primarily by weight limitations and islimited only by providing an annulus between the perimeter of thestabilizer and the vessel wall large enough to permit catalyst to flowdownwardly while simultaneously passing stripping gas in an upwardlydirection.

The vortex finder is not critical to cyclone performance provided thevortex stabilizer means are located a short distance from the vortexoutlet, i.e., at least about 2-3 vortex outlet tube diameters. However,if the vortex finder is located at a greater distance, say 5-8 vortexoutlet tube diameters, then it is preferred that the vortex stabilizermeans contain a vortex finder. Preferably such a vortex finder would begreater than about one third the vortex length.

Based on aerodynamic studies, vortex stabilization appears desirable forincreasing separation efficiency while minimizing both pressure loss anderosion. Vortex stabilizers reduced the pressure drop across the modelcyclone by 10-15% even though the peak swirl velocities weresignificantly increased. This behavior is exceptional in cyclones sinceincreasing swirl almost always raises the pressure loss. As the pressuredrop goes down, vortex stabilization seems to reduce the turbulentenergy dissipation in cyclones.

These studies led to the discovery that when a suitable vortexstabilizer is present in a cyclone, a fluidized bed stripping sectioncan be added to the cyclone. In the apparatus of the invention strippinggas flows upwardly counterflow to the downward flow of catalyst withoutaffecting the efficiency of the cyclone separator. Without the vortexstabilizer means even small amounts of stripping gas into the bottom ofthe cyclone separator disrupted the vortex and rapidly destroyed itsefficiency. These findings were verified in a laboratory test loop whichis discussed below.

There is a fundamental difference between the stabilizer disk and avertical tube as internals in the cyclone/stripper. The stabilizer diskcenters the vortex in the upper cyclone section and decouples it fromthe stripping section below. Steam from the stripping section must sweeparound the disk, displacing the hydrocarbon vapor from that region.However, the steam may entrain catalyst if the velocity through theannular space around the disk gets too high. But "too high" is at least10 ft/sec and probably higher.

The vertical tube, as used in Mobil's U.S. Pat. No. 4,043,899, couplesthe vortices of the upper cyclone with those of the stripper section.The central opening is essential to the Mobil design but allows catalystto be entrained from the stripping section up the vortex of the cyclone.Much lower steam velocities are required to entrain fluidized catalystup the central tube than would be required to entrain catalyst from thewall.

Therefore, the Mobil design is unsuitable for incorporating a fluidizedbed stripper in the bottom of the vessel. The upflow of steam woulddisrupt the cyclonic motion in both the tangential stripper section thatMobil uses and in the cyclone proper, above. Unacceptable catalystcarryover would result.

A test loop was constructed of Plexiglass® (a shatter-resistantsynthetic acrylate resin) as shown in FIG. 1. Catalyst enters the bottomof a 3"×14' riser 10 and is transported by air which enters through aconcentric 11/2" nozzle 11. The differential pressure (ΔP) 12 across theriser was not measured precisely, but was on the order of 1" of H₂ O.Air flow rates of 64 to 103 SCFM were used in the riser 10. These ratescorrespond to superficial velocities in the riser of 22 to 35 ft/sec(4.9 to 7.9 lbs/minute of air). Measurement of air rate was viarotometer. Catalyst flow rates in the riser were varied from 4.6 to 20lbs/minute. Control of solids flow rate was by setting a pinch clamp 13in a 3" dia. standpipe 14 between the catalyst hold tank 15 and theriser 10. The catalyst rate was measured by closing a pinch clamp 16between the stripper cyclone 17 and the catalyst hold tank 15 andmeasuring the rate of level increase in the stripper cyclone body. Forthis measurement air was turned off to the stripper cyclone 17 and acatalyst density of 50 lbs/ft³ was assumed.

At the top of the riser 10 there is a right angle turn 18 and atransition 19 from a 3" pipe (7.07 sq. inch) to a 6" high×11/2" widerectangular tangential cyclone inlet 31 (9 sq. inch). Gas velocities atthe cyclone inlet were varied from 17 to 27.5 ft/second.

Gas exits from the stripper cyclone 17 via a 3" ID pipe 20. A secondarycyclone 21 collects the catalyst from the stripper cyclone overhead. Apaper filter 22 allows clean gas to pass to the atmosphere and catchescatalyst which escapes from the secondary cyclone.

Catalyst exits from the stripper cyclone 17 through a standpipe 23. Thepinch clamp 16 is used to control the catalyst level in the bottom ofthe stripper cyclone 17. The catalyst hold tank 15 below the strippercyclone 17 provides a reservoir which feeds the riser through a 3"standpipe 14.

A detailed diagrammatic elevation view of the stripper cyclone 17 isshown in FIG. 2. The cyclone zone 24 was made from a 6 inch ID pipe andcontained a vortex finder 25 and a vortex stabilizer 26 located asuitable distance (6-18 inches) from the bottom of the clean gas outletpipe 20. This distance defines the vortex length, VL. Below the vortexstabilizer 26 and stripping zone 27, a catalyst bed level 28 wasmaintained. The stripping zone 27 was also made from a 6 inch ID pipe.Vortex finder 26 is supported by support means 38 connecting theinterior wall of the hollow housing to define an annular opening 39through which catalyst pass downward and stripping gas pass upwardsimultaneously. The clean gas outlet 20 was a 3 inch ID pipe with 1/8"wall thickness and extended 7 inches through the swirl-inducing zone 30to the top of the cyclone zone 24. The catalyst outlet 23 was 3 inch IDpipe.

The vortex stabilizer 26 was 4 inches in diameter (for most of thetests), 1/2 inch thick at the edge and 1 inch thick in the center. Thevortex finder 25 was 21/2 inches long, 1/2 inch diameter at the base and1/4 inch diameter at the top. Air and ammonia or water were injectedthrough an annular plenum 33 and a sintered stainless steel ring 34 intothe bottom of the catalyst bed 35. The ammonia or water were added tominimize static electricity in the apparatus.

Bed height (BH), disengaging height (DH) and vortex length (VL) were allvaried during the tests.

The overall efficiency of the stripper cyclone 17 was measured byweighing the underflow from the secondary cyclone 21 (FIG. 1). This wasnot rigorously correct because the fines collected on the paper filterat the top of the secondary cyclone were not measured. However, theerror was small. After several measurements of efficiency, the amount offines on the filter was trivial compared to the amount of catalystcollected from the secondary cyclone underflow during any singlemeasurement of efficiency.

The invention will now be illustrated with reference to the followingExamples, which are intended to be a complete specific embodiment of theinvention and are not intended to be regarded as a limitation thereof.

EXAMPLE 1

A series of tests was undertaken using the test loop and strippercyclone shown in FIGS. 1 and 2 and described above. Commercial fluidcatalytic cracking catalyst was used as the solid and air was used asboth transparent gas (simulating gaseous hydrocarbons) and as strippinggas (simulating steam). The vortex stabilizer for this test series was a4" diameter disk, 1/2-inch thick at the edge and 1-inch thick at thecenter. A vortex finder, 21/2 inches long×1/2-inch diameter at thebase×1/4-inch diameter at the top, was mounted at the center of thestabilizer plate.

Tests of stripper cyclone efficiency were made with and without thevortex stabilizer. Without the stabilizer, introducing air to thestripper caused a considerable increase in solids loss in the strippercyclone overflow. With the stabilizer in place considerable air can beintroduced to the stripper with only a minor effect on the rate ofcatalyst loss in the stripper cyclone overflow. The data from thesetests are plotted in FIG. 3 and the test results are given in Table 1.The air rate to the stripper depends upon catalyst circulation rate andcyclone (bed) cross sectional area. However, to put the rates inperspective, 6 SCFM air to the stripper results in a bed superficialvelocity of 0.5 ft/sec. For a commercial unit with, say, 40 tons perminute catalyst circulation and a 15 ft cyclone diameter, 0.5 ft/seccorresponds to 2.9 lbs of stripping steam/1000 lbs of catalyst in a 950°F., 20 psig situation. Thus the air rates used in this test are close tothe steam rates required for reasonable stripping.

These tests show that with a vortex stabilizer, an upflowing gassuperficial velocity of 0.5-0.62 ft/sec (6 to 9.5 SCFM) does not causeany appreciable deterioration in separation efficiency. Superficialvelocities of up to about 0.9 ft/sec (about 11 SCFM) can be toleratedwithout much loss in separation efficiency.

                  TABLE 1                                                         ______________________________________                                        STRIPPER CYCLONE COLLECTION EFFICIENCY                                                         Cat                Bed  Cat.                                 Test SCFM Air    Flow,    VL,  DH,  Ht., Overhead,                            No.  Riser   Stripper                                                                              lbs/min                                                                              in.  in.  in.  Gm/Min                             ______________________________________                                         1   95.2    0       14.6   11   18    6   4.1                                 2   "       3       "      "    "    "    3.8                                 3   "       6       "      "    "    "    4.3                                 4   "       7.5     "      "    "    "    4.0                                 5   "       9       "      "    "    "    15.0                                6   87.7    0       14.4   11   18    6   3.5                                 7   "       6       "      "    18    6   3.4                                 8   "       9       "      "    18    6   7.9                                 9   "       11      "      "    18    6   20.1                               10   "       6       "      "    18    6   4.1                                11   "       6       "      "    10   14   4.8                                12   95.2    0       23.0   11   18    6   13.7                               13   "       0       13.0   "    18    6   3.2                                14   "       6       13.0   "    10   14   3.7                                15   "       7.5     13.0   "    10   14   5.6                                16   "       9       13.0   "    10   14   10.4                               17   95.2    0       13.6   *    25   10   13.3                               18   "       0       "      *    25   10   15.8                               19   "       3       "      *    25   10   113.7                              20   90.4    0       17.3    7   18   10   3.1                                21   "       6       "      "    14   14   4.1                                22   "       0       "      "    18   10   3.2                                23   "       9       "      "    14   14   7.4                                24   "       3       "      "    14   14   2.5                                25   "       7.5     "      "    14   14   5.6                                26   "       11      "      "    14   14   25.3                               27   "       0       "      "    18   10   4.2                                28   "       0       "      "    18   10   2.6                                29   "       6       "      "    10   18   3.2                                30   "       11      "      "    15   13   11.3                               ______________________________________                                         *No vortex stabilizer.                                                   

EXAMPLE 2

Another series of tests was made in the test loop and stripper cyclonedescribed in Example 1 using a vortex length of 11 inches, a solids flowrate of 15.5 pounds per minute through the riser along with 88.5 SCFM ofair.

This series of tests involved injecting helium into the riser gas andmeasuring the helium concentration in the gas exiting with the catalyst.The sampling point was found unaerated catalyst in the stripperstandpipe. Assuming a bulk density of 40 lbs/ft³ for catalyst in thestandpipe, gas flow down the stripper standpipe would be about 0.5 SCFM.The tests, as shown in FIG. 4, indicate that by introducing air to thestripper riser, gas was effectively excluded from the stripperstandpipe. At 6 SCFM air to the stripper, bed height in the stripper hadlittle effect on the exclusion of riser gas from the stripper standpipe.In fact, even without a vortex stabilizer, little of the riser gas foundits way to the stripper standpipe.

These helium tracer studies show that a very small percentage of gascontained in the riser reaches the stripper cyclone standpipe when asuitable amount of stripping gas is added to the stripper cyclone of theinvention which contains stabilizer means, a catalyst bed and suitabledisengaging height (DH). The latter ranged from 10-18 inches for thesetests and no appreciable difference in efficiency was noted.

EXAMPLE 3

Another series of tests was made using the test loop and strippercyclone of Example 1 wherein the vortex stabilizer dimensions werevaried. For this series of tests the conditions were as follows: 6"diameter cyclone, 7" vortex length, 12.5" Disengaging Height, 7.5" BedHeight, 3" diameter gas outlet tube, 1" diameter catalyst underflowtube, 90.9 SCFM Air and ˜20 lbs/min catalyst to cyclone inlet, vortexstabilizer pin=2.5".

Table 2 contains data on cyclone collection efficiencies for severaldifferent vortex stabilizer diameters. The grams per minute of catalystwhich escapes the cyclone as overflow was measured for each stabilizerplate diameter. With no stabilizer (zero plate diameter) introducingeven a small amount of upflowing air caused a major loss of efficiency.A three inch diameter plate provided some improvement while a four inchdiameter plate provided significant improvement. The 41/2 inch and 5inch plates provided further but less dramatic improvement. In scalingup the design from test loop to commercial size, the pertinent factor isthe ratio between the vortex outlet tube diameter (clean gas outlet) andthe stabilizer plate diameter. In the test cyclone, the vortex outlettube diameter was three inches. Taking the 41/2 inch diameter plate asan acceptable compromise between efficiency and stabilizer weight, theratio between plate diameter and vortex tube diameter should be about1.5.

Similar tests were made to determine the effect of vortex stabilizer pinlength. Little effect was noted and a pin length of about one-third thevortex length seems adequate.

EXAMPLE 4

Another type of vortex stabilizer was tested using the test loop andstripper cyclone of Example 1. The conditions were the same as those forExample 3, except that a 4-inch diameter vortex stabilizer plate with a1-inch diameter vortex finder pin was used and the plate and pin had anaxial hole through them. Two hole sizes were tested (3/8" and 5/8" dia.)and the results are shown in Table 3.

In vortex stabilizers containing an axial hole a gas upflow existsthrough the hole due to the pressure differential created by vortex flowin the cyclone. Process gas laden with solid particulates enters theswirl zone through a tangential inlet. Primary separation of solids andgas takes place by centrifugal action in the upper cyclonic section ofthe device above the vortex stabilizer. Most of the incoming gas thusseparated from particulates is removed through the gas outlet. A smallportion of the process gas is allowed to flow co-currently with thesolids which travel down through the annulus between the body of thecyclone and the vortex stabilizer in their natural, unrestricted helicalpattern. Most of the entrained gas is separated from the solids in thestripping zone below the vortex stabilizer by virtue of the pressuredifferential existing across the axial hole and is returned to the gasoutlet through the core of the cyclone.

Solid particulates fall downwardly through the stripping zone into abubbling dense bed where the removal of process gas is completed bystripping the solids with an inert gas. Stripping gas flows upwardlythrough the axial hole to the low pressure core of the vortex and to thegas outlet together with stripped and entrained portions of processvapor.

High solids removal efficiency is obtained in the device by providingthe above mentioned small but positive co-current downflow of processgas with the solids in the annulus between the stabilizer and thecyclone vessel wall. The amount of gas downflow through the annulus iskept as small as practical by proper design to reduce the inward radialvelocity of the gas as it separates from the solids in the lower sectionto avoid re-entrainment of solids through the axial hole. A sufficientlylarge disengaging height is provided above the dense bed to prevententrainment from the dense bed and to further minimize the radialvelocity. Excessive amounts of gas downflow also increases the effectiveresidence time in the cyclone and is to be avoided where this isundesirable. The performance of the cyclone can be tailored to desiredobjectives by proper choice of cyclone, and in particular, axial holedimensions.

Peripheral removal of solids from the primary separation chamber at highvelocities with co-current gas flow avoids flow problems encountered indischarge of sticky solids through conventional cyclone dip-legs andpermit high solids discharge rates without plugging problems throughcyclones of relatively small dimension having low gas residence times.

                  TABLE 2                                                         ______________________________________                                        EFFECT OF VORTEX STABILIZER ON STRIPPER                                       CYCLONE COLLECTION EFFICIENCY                                                              Catalyst in Stripper Cyclone Overflow,                           Air To Strip-                                                                              Grams/Minute                                                     Com-  per, SCFM           3"   4"                                             parison                                                                             (Upflowing No       Dia  Dia  41/2" Dia                                                                            5" Dia                             No.   Air)       Stabilizer                                                                             Plate                                                                              Plate                                                                              Plate  Plate                              ______________________________________                                        1     0           0.97    --   --   --     --                                 2     2          7.9      --   --   --     --                                 3     3          20.4      0.26                                                                              0.17 0.16   0.11                               4     6          --        3.34                                                                              0.25 0.17   0.11                               5     7.5        --       --   0.20 --     --                                 6     9          --       44.6 0.45 0.35   0.14                               7     10.5       --       --   6.1  1.9    0.77                               8     11.25      --       --   --   --     5.5                                9     12         --       --   --   --     65.8                               ______________________________________                                    

                  TABLE 3                                                         ______________________________________                                        EFFECT OF VORTEX STABILIZER ON STRIPPER CYCLONE                               COLLECTION EFFICIENCY                                                                           Catalyst in Stripper                                                          Cyclone Overflow,                                                  Air to Stripper,                                                                         Grams/Minute                                                Comparison                                                                             SCFM         No       3/8" Dia*                                                                            5/8" Dia*                               No.      (Upflowing Air)                                                                            Stabilizer                                                                             Hole   Hole                                    ______________________________________                                        1        0            0.97     2.6    --                                      2        2            7.9      9.5    13.0                                    3        3            20.4     --     --                                      4        6            --       18.6   43.5                                    5        7.5          --       19.6   --                                      6        9            --       21.9   --                                      7        10.5         --       26.9   --                                      ______________________________________                                         *4" diameter plate, 1" diameter pin, hole through pin and plate.         

Other embodiments of the invention will be apparent to those skilled inthe art from a consideration of this specification or from practice ofthe invention disclosed herein. It is intended that the specificationand examples be considered as exemplary only, with the true scope andspirit of the invention being indicated by the following claims.

What is claimed is:
 1. An apparatus for separating suspensions ofcatalyst particles and gaseous hydrocarbons and for strippinghydrocarbons from said catalyst particles after traversing a riserconduit which comprises:(a) an upright hollow housing having a lowerportion, a middle portion an upper portion, a gaseous hydrocarbon vortexoutlet with a diameter in said upper portion of said housing forremoving clean gaseous hydrocarbons, and a stripped catalyst outletmeans in said lower portion of said housing for removing strippedcatalyst, said housing having a tangential inlet means in said upperportion to form a swirl zone wherein suspensions of catalyst particlesand gaseous hydrocarbons entered through said inlet means form a fluixvortex; (b) a vortex stabilizer means having a perimeter and coaxiallymounted in said middle portion of said housing and having a diameter ofat least the diameter of said gaseous hydrocarbon vortex outlet andpositioned a distance from said gaseous hydrocarbon vortex outlet meansto define a cyclone zone, wherein catalyst particles are separated fromgaseous hydrocarbons to form a clean fluid, wherein said vortexstabilizing means stabilizes and centers said vortex to minimizereentrainment of said particles into said clean gaseous fluid, whereinsaid vortex stabilizing means is spaced a distance equal to a distanceof at least two of said gaseous hydrocarbon vortex outlet diametersbelow said hydrocarbon vortex outlet and wherein said vortex stabilizermeans is supported, by vortex stabilizer support means in said housingto provide an annular space intermediate said perimeter of said vortexstabilizer means and said housing sufficient to pass separated catalystdownward through said annular space into a stripping zone and passstripping gas upward through said annular space into said cyclone zone;(c) means for supporting a fluidized catalyst bed below said vortexstabilizer means near said bottom of said hollow housing and having afluidized bed of catalyst being supported thereon and defining,intermediate said fluidized catalyst support means and said vortexstabilizer means, a stripping zone in gaseous communication with saidcyclone zone through said annular space and including a catalystdisengaging space of sufficient height to avoid slugs of catalystcarryover into said cyclone zone and where, in said stripping zone,gaseous hydrocarbons are stripped from the catalyst particles to therebyterminate cracking reactions of said hydrocarbons; and (d) means forinjecting stripping gas into said fluidized catalyst to minimizeadsorbed hydrocarbons on the catalyst particles.
 2. The apparatus ofclaim 1 wherein the stabilizer means has attached to the center thereofand extending upwardly into the cyclone zone a vortex finder rod.
 3. Theapparatus of claim 2 wherein the vortex finder rod has a length of atleast one-third the length of the vortex.
 4. The apparatus of claim 1wherein said vortex stabilizer means comprises a solid disk or plate. 5.The apparatus of claim 4 wherein said vortex stabilizer means hasattached thereto an axial upwardly extending vortex finder rod.
 6. Theapparatus of claim 5 wherein said vortex finder rod and said vortexstabilizer means have a length, wherein said length of said vortexfinder rod is equal to at least one third the length of said vortexstabilizer means.